1st CREMA / C2NET Industrial Workshop Cloud-based Rapid Elastic MAnufacturing Machinery Maintenance Aizea Lojo Juan López de Armentia Xabier De Carlos Mikel Anasagasti Jon Rodriguez 1st CREMA / C2NET Industrial Workshop

Fagor Arrasate founder member of the Mondragon Corporation world leader in the design and manufacture of mechanical and hydraulic presses, complete stamping systems, transfer presses and many other machines metal forming manufacturer with the world’s largest product portfolio.

IK4-Ikerlan Industry 4.0 projects Electronics, Information and Communication Technologies Specialists in embedded HW/SW. Strongly committed to industrial dependability and industrial cyber security. 30 engineers with certification in dependable system’s development. Private research centre not-for-profit, oriented to public service Leader in transferring technology to industry Member of the IK4 Research Alliance Energy and Power Electronics Focussing on developing energy-efficient solutions. Advanced Manufacturing Product design, reliability and associated services. Development of control, monitoring and smart maintenance solutions. Industry 4.0 projects

Goizper one of the leading technology suppliers in power transmission components: brakes, clutches, turning systems, gear boxes, cams, elevators, etc. manufactures and supplies customized power transmission components to meet market needs in sectors like metal forming, automotive, aeronautics, packaging, construction, marine, machine tools, etc. focused on the design, manufacture and marketing of manual sprayers and dusters for treatments in farming, gardening, industry, construction, cleaning, pest control and vector control.

ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS In this presentation EXISTING PROBLEMS ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS

ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS In this presentation EXISTING PROBLEMS ON MACHINERY MAINTENANCE ! CONTEXT EXISTING PROBLEMS POSSIBLE SOLUTIONS HOW CREMA SOLVES THESE PROBLEMS

Machinery Maintenance ! EXISTING PROBLEMS POSSIBLE SOLUTIONS CONTEXT

Machinery Maintenance: Context Mechanic Press machine: A machine that accumulates energy by means of a flywheel and transmits it through a Clutch Brake and a Crankshaft to a die. Clutch brake: A Clutch Brake is a mechanical device that engages and disengages the power transmission, especially from driving to driven shaft. Clutches are used whenever the transmission of power or motion must be controlled.

Machinery Maintenance: Context Clutch brake break  Press Machine Stopped Press machine stopped TAS team travel Analyse clutch brake Order supply Installation & Setup Press Machine DOWNTIME operators stopped, customer parts deliveries in risk, …

Machinery Maintenance: Context Fagor and Goizper TAS teams urgently travel to the customer’s plant Press machine stopped TAS team travel Analyse clutch brake Order supply TAS team travel Installation & Setup Problems and delays: Visa, special tools, weather, spare parts delivery issues, …

Machinery Maintenance: Context Analisis of the clutch brake at the customers plant Press machine stopped TAS team travel Analyse clutch brake Order supply TAS team travel Installation & Setup Sometimes TAS teams can fix the problem, but others not …

Machinery Maintenance: Context New clutch brake required: order manufacturing to the supplier. designed specifically for each press machine usually there is not stock for this part Press machine stopped TAS team travel Analyse clutch brake Order supply TAS team travel Installation & Setup Time required  Press machine downtime increase

Machinery Maintenance: Context TAS teams travel to the customer’s plant and the new clutch brake is delivered Press machine stopped TAS team travel Analyse clutch brake Order supply TAS team travel Installation & Setup

Machinery Maintenance: Context When TAS teams and supply are at the customers plant, clutch brake installation and set up is performed. Press machine stopped TAS team travel Analyse clutch brake Order supply TAS team travel Installation & Setup

Machinery Maintenance ! EXISTING PROBLEMS POSSIBLE SOLUTIONS CONTEXT

Machinery Maintenance: Problems Now The machinery monitoring and maintenance is reactive and manual. Data is not collected continuously. The customer directly reports the errors. Specialized teams connect remotely to perform teleservice. Cybersecurity problems. High Costs!! lack of clutch brake data monitoring lack of a fast and reliable spare parts management 1. High costs for all the chain (Press machine user, Press manufacturer, Clutch Brake manufacturer) due to: 2.Neccesity of downtime decrease because of a Clutch Brake failure Downtime losses! Need to minimize downtime when a clutch break failure occurs.

Machinery Maintenance ! EXISTING PROBLEMS POSSIBLE SOLUTIONS CONTEXT

Machinery Maintenance: Solution Now The machinery monitoring and maintenance is reactive and manual. Data is not collected continuously. The customer directly reports the errors. Specialized teams connect remotely to perform teleservice. Cybersecurity problems. Ideally Automatic monitoring of the machine with local persistence. Send data continuously to the cloud. Anticipate to the machine errors defining some KPI’s and Alarms. Availability of these data through some kind of application. More secure solutions through CREMA platform. 1. High costs for all the chain (Press machine user, Press manufacturer, Clutch Brake manufacturer) due to: 2.Neccesity of downtime decrease because of a Clutch Brake failure

ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS In this presentation EXISTING PROBLEMS ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS

ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS In this presentation EXISTING PROBLEMS ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS

How CREMA will solve problems Define machine maintenance process and execute. Cloud Collaborative Process Design Time Environment Cloud Process and Messaging Runtime Environment

How CREMA solves problems INGEST PERSIST MONITOR MAINTENANCE PLAN DATA ANALYTICS COLLECT TRANSPORT

How CREMA solves problems COLLECT MONITOR MAINTENANCE PLAN DATA ANALYTICS PERSIST INGEST TRANSPORT

How CREMA will solve problems Collect data from press machine & clutch brake sensors Clutch Brake

How CREMA will solve problems Collect data of each stroke from press machine & clutch brake sensors LOCAL DATA FILE persist bus sensor signals

How CREMA will solve problems Collect data from press machine & clutch brake sensors LOCAL DATA FILE Unifies data coming from press machine PLC and clutch brake sensors. Data is persisted in a local file into an Industrial PC.

How CREMA will solve problems Collect data from press machine & clutch brake sensors each stroke ≈ 3-4 s

How CREMA solves problems COLLECT MONITOR MAINTENANCE PLAN DATA ANALYTICS PERSIST INGEST TRANSPORT

How CREMA solves problems Get data from datalogger and transport to CREMA. LOCAL DATA FILE SEND TO CREMA

How CREMA solves problems COLLECT MONITOR MAINTENANCE PLAN DATA ANALYTICS PERSIST INGEST TRANSPORT

How CREMA solves problems Ingests data from the press machine and clutch brake, and processes it Data Harmonization Services Transform data into CREMA format Message Bus

How CREMA solves problems COLLECT MONITOR MAINTENANCE PLAN DATA ANALYTICS PERSIST INGEST TRANSPORT

How CREMA solves problems Monitor ingested press machine & clutch brake data. Customer is able to define business rules & thresholds. Monitoring and Alerting

How CREMA solves problems Monitor ingested press machine & clutch brake data. Data is monitored and alarms are triggered based on the previously defined business rules & thresholds. Data collected per millisecond per day many alarm triggered. Per alarm save the starting date and hour and the end time date and time. For not annoying the operator, trigger alarm if it is triggered more than 15 times in one day. Have a list with the alarm historic entering from w. Monitoring and Alerting

How CREMA solves problems COLLECT MONITOR MAINTENANCE PLAN DATA ANALYTICS PERSIST INGEST TRANSPORT

How CREMA solves problems CREMA provides mechanisms to analyze press machine & clutch brake data Press machine & clutch brake data Big Data Analytics

How CREMA solves problems COLLECT MONITOR MAINTENANCE PLAN DATA ANALYTICS PERSIST INGEST TRANSPORT

How CREMA solves problems CREMA automatically plans maintenance based on alarms (monitor) and analysed data. Decrease machine downtime and maintenance cost. TAS Teams Design Time & Runtime Optimisation Optimized maintenance planning Suppliers Requirements

How CREMA solves problems COLLECT MONITOR MAINTENANCE PLAN DATA ANALYTICS PERSIST INGEST TRANSPORT

How CREMA solves problems Persist data ingested by CREMA into a database. Press machine & clutch brake data Cloud-based RAID Infraestructure

MACHINERY MAINTENANCE: BENEFITS FROM CREMA

Machinery Maintenance: CREMA Benefits INGEST PERSIST MONITOR MAINTENANCE PLAN DATA ANALYTICS COLLECT TRANSPORT CREMA provides: Automatic monitoring of the press machine. Ingest data from the press machine providing mechanisms for data analysis and monitor. Preventive maintenance: Anticipate to the machine errors and automatically schedule maintenance. CREMA provides mechanisms to minimize the production downtimes of the press machine and its components. Automatic monitoring of the press machine with local persistence. Send data continuously to the cloud. Anticipate to the machine errors defining some KPI’s and Alarms. Availability of these data through some kind of application.

Machinery Maintenance: CREMA Benefits INGEST PERSIST MONITOR MAINTENANCE PLAN DATA ANALYTICS COLLECT TRANSPORT ↓DOWNTIME = ↑ CUSTOMER PRODUCTIVITY ↓TAS & SUPPLIER COST CREMA provides mechanisms to minimize the production downtimes of the press machine and its components. Automatic monitoring of the press machine with local persistence. Send data continuously to the cloud. Anticipate to the machine errors defining some KPI’s and Alarms. Availability of these data through some kind of application.

Machinery Maintenance: CREMA Benefits Expected impact of applying CREMA on machinery maintenance: ↓ time of machine downtime ↓unscheduled machine downtimes Up to 60% reduction of unscheduled machine downtimes on customers due to a better tracking of critical machine components performance. 15% reduction of machine downtime on customers because of the increased visibility of machines behaviour in customers by means of a better management of expected future needs. Up to 50% reduction of intervention time on customers because GOIZ can manufacture in advance critical components sub-assemblies to simplify substitution operations on customers. 25% reduction of intervention costs by a better coordination between customers, spare parts suppliers (GOIZ) and TAS companies avoiding additional costs and time due to a non-presence of spare parts on the client or non-scheduled machine downtime to perform the intervention ↓ intervention time ↓ intervention costs

Machinery Maintenance CREMA Cloud-based Rapid Elastic MAnufacturing manasagasti@goizper.com| alojo@ikerlan.es | j.rodriguez@koniker.coop 1st CREMA / C2NET Industrial Workshop